US11296573B2 - Stator winding for rotating electric machine, and manufacturing method therefor - Google Patents

Stator winding for rotating electric machine, and manufacturing method therefor Download PDF

Info

Publication number
US11296573B2
US11296573B2 US16/827,920 US202016827920A US11296573B2 US 11296573 B2 US11296573 B2 US 11296573B2 US 202016827920 A US202016827920 A US 202016827920A US 11296573 B2 US11296573 B2 US 11296573B2
Authority
US
United States
Prior art keywords
portions
conductor
terminal
lead wires
electric machine
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active, expires
Application number
US16/827,920
Other versions
US20200328647A1 (en
Inventor
Kota Katsuragi
Shinji Kawaguchi
Kohei Yasuda
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Mitsubishi Electric Corp
Original Assignee
Mitsubishi Electric Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Mitsubishi Electric Corp filed Critical Mitsubishi Electric Corp
Assigned to MITSUBISHI ELECTRIC CORPORATION reassignment MITSUBISHI ELECTRIC CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KATSURAGI, KOTA, KAWAGUCHI, SHINJI, YASUDA, KOHEI
Publication of US20200328647A1 publication Critical patent/US20200328647A1/en
Application granted granted Critical
Publication of US11296573B2 publication Critical patent/US11296573B2/en
Active legal-status Critical Current
Adjusted expiration legal-status Critical

Links

Images

Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/32—Windings characterised by the shape, form or construction of the insulation
    • H02K3/38—Windings characterised by the shape, form or construction of the insulation around winding heads, equalising connectors, or connections thereto
    • H02K15/0062—
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/30—Manufacture of winding connections
    • H02K15/32—Manufacture of terminal arrangements; Connecting the terminals to external circuits
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/30—Manufacture of winding connections
    • H02K15/33—Connecting winding sections; Forming leads; Connecting leads to terminals
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/46—Fastening of windings on the stator or rotor structure
    • H02K3/50—Fastening of winding heads, equalising connectors, or connections thereto
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K1/00—Details of the magnetic circuit
    • H02K1/06—Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/22—Rotating parts of the magnetic circuit
    • H02K1/27—Rotor cores with permanent magnets
    • H02K1/2706—Inner rotors
    • H02K1/272—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis
    • H02K1/274—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets
    • H02K1/2753—Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets the rotor consisting of magnets or groups of magnets arranged with alternating polarity
    • H02K1/276—Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM]
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K2203/00—Specific aspects not provided for in the other groups of this subclass relating to the windings
    • H02K2203/06—Machines characterised by the wiring leads, i.e. conducting wires for connecting the winding terminations
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K5/00—Casings; Enclosures; Supports
    • H02K5/04—Casings or enclosures characterised by the shape, form or construction thereof
    • H02K5/16—Means for supporting bearings, e.g. insulating supports or means for fitting bearings in the bearing-shields
    • H02K5/173—Means for supporting bearings, e.g. insulating supports or means for fitting bearings in the bearing-shields using bearings with rolling contact, e.g. ball bearings
    • H02K5/1732—Means for supporting bearings, e.g. insulating supports or means for fitting bearings in the bearing-shields using bearings with rolling contact, e.g. ball bearings radially supporting the rotary shaft at both ends of the rotor

Definitions

  • the present invention relates to a stator winding for a rotating electric machine in which conductors of a plurality of lead wires are electrically connected to each other by joining portions, and to a manufacturing method therefor.
  • stator winding for a rotating electric machine which includes a plurality of lead wires and joining portions.
  • the plurality of lead wires each include a conductor and an insulating film provided on side surfaces of the conductor.
  • the joining portions are configured to electrically connect the conductors of the plurality of lead wires. Terminal portions of the plurality of lead wires each have the conductor exposed therefrom to form a conductor exposure portion having the joining portion connected thereto (for example, see Japanese Patent No. 6448664).
  • the present invention has been made to solve the problem described above, has an object to provide a stator winding for a rotating electric machine which is capable of reducing a dimension of the stator winding in an axial direction of a rotating electric machine, and a manufacturing method therefor.
  • a stator winding for a rotating electric machine including: a plurality of lead wires each including a conductor and an insulating film provided on side surfaces of the conductor; and a joining portion configured to join terminal portions of the plurality of lead wires to each other, to thereby electrically connect the conductors of the plurality of lead wires, wherein the plurality of lead wires each include: a conductor exposure portion, which is provided at a portion of the terminal portion at which the terminal portions of the plurality of lead wires face each other, has the conductor exposed thereat, and has the joining portion connected thereto; and an insulating film remainder portion, which is provided at a portion of the terminal portion of the lead wire excluding the conductor exposure portion, and has the conductor covered with the insulating film, and wherein a portion of the insulating film in the insulating film remainder portion is provided in a periphery of the joining portion.
  • stator winding for a rotating electric machine of the present invention it is possible to reduce a dimension of the stator winding in an axial direction of a rotating electric machine, and a manufacturing method therefor.
  • FIG. 1 is a partial sectional view for illustrating a rotating electric machine according to a first embodiment of the present invention.
  • FIG. 2 is a perspective view for illustrating a stator of FIG. 1 .
  • FIG. 3 is a sectional view for illustrating main parts of the stator of FIG. 2 .
  • FIG. 4 is a view for illustrating a radially inner portion of the stator of FIG. 3 as viewed toward a radially outer side.
  • FIG. 5 is a perspective view for illustrating a terminal portion of FIG. 4 .
  • FIG. 6 is a view for illustrating a state in which two terminal portions are joined to each other through laser radiation.
  • FIG. 7 is a plan view for illustrating the two terminal portions of FIG. 6 .
  • FIG. 8 is a perspective view for illustrating the two terminal portions joined to each other.
  • FIG. 9 is a sectional view for illustrating main parts of the stator including the two terminal portions joined to each other.
  • FIG. 10 is a flowchart for illustrating a manufacturing method for a stator winding for a rotating electric machine according to the first embodiment of the present invention.
  • FIG. 11 is a front view for illustrating main parts of a stator winding for a rotating electric machine according to a second embodiment of the present invention.
  • FIG. 12 is a perspective view for illustrating a terminal portion of a stator winding for a rotating electric machine according to a third embodiment of the present invention.
  • FIG. 13 is a front view for illustrating two terminal portions joined to each other.
  • FIG. 14 is a perspective view for illustrating a modification example of the terminal portion.
  • FIG. 15 is a front view for illustrating a modification example of two terminal portions joined to each other.
  • FIG. 16 is a perspective view for illustrating main parts of a stator winding for a rotating electric machine according to a fourth embodiment of the present invention.
  • FIG. 17 is a front view for illustrating main parts of the stator winding of FIG. 16 .
  • FIG. 18 is a perspective view for illustrating a terminal portion of a stator winding for a rotating electric machine according to a fifth embodiment of the present invention.
  • FIG. 19 is a perspective view for illustrating a state in which a joining member is mounted to the terminal portion of FIG. 18 .
  • FIG. 20 is a front view for illustrating the terminal portion and the joining member of FIG. 19 .
  • FIG. 21 is a plan view for illustrating two terminal portions held in press contact with each other.
  • FIG. 22 is a perspective view for illustrating a modification example of the terminal portion.
  • FIG. 23 is a plan view for illustrating a modification example of the two terminal portions held in press contact with each other.
  • FIG. 24 is a perspective view for illustrating a terminal portion of a stator winding for a rotating electric machine according to a sixth embodiment of the present invention.
  • FIG. 25 is a plan view for illustrating two terminal portions joined to each other.
  • FIG. 26 is a sectional view taken along the line XXVI-XXVI of FIG. 25 as viewed in the direction indicated by the arrows.
  • FIG. 27 is a sectional view for illustrating main parts of a stator including two terminal portions joined to each other.
  • FIG. 1 is a partial sectional view for illustrating a rotating electric machine according to a first embodiment of the present invention.
  • a rotating electric machine 1 includes a shaft 2 configured to transmit torque to an outside.
  • an axial direction corresponds to a direction along the shaft 2
  • a radial direction corresponds to a radial direction with the shaft 2 being a center
  • a circumferential direction corresponds to a circumferential direction with the shaft 2 being a center.
  • the rotating electric machine 1 is illustrated in sectional view on a right side with respect to a plane passing through the center of the shaft 2 and extending along the shaft 2 , and is illustrated in front view on a left side.
  • the rotating electric machine 1 includes a housing 3 , a stator 4 , a rotor 5 , and a plurality of bearings 6 .
  • the stator 4 is supported on the housing 3 , and is configured to generate a rotational magnetic field.
  • the rotor 5 is provided on a radially inner side with respect to the stator 4 .
  • the plurality of bearings 6 are supported on the housing 3 , and are configured to rotatably support the shaft 2 .
  • the rotor 5 is supported on the housing 3 through intermediation of the shaft 2 and the bearings 6 .
  • the rotor 5 rotates relative to the stator 4 in the circumferential direction.
  • a gap is defined between the stator 4 and the rotor 5 in the radial direction.
  • the rotor 5 is fixed to the shaft 2 , and includes a rotor core 501 and a plurality of permanent magnets 502 .
  • the rotor core 501 allows magnetic fluxes to pass therethrough.
  • the plurality of permanent magnets 502 are embedded in the rotor core 501 .
  • FIG. 2 is a perspective view for illustrating the stator 4 of FIG. 1 .
  • the stator 4 includes a stator core 401 and a plurality of stator windings 402 .
  • the stator core 401 has an annular shape.
  • the plurality of stator windings 402 are supported on the stator core 401 , and are configured to generate a magnetic field through feeding of a current therethrough.
  • the stator core 401 has a plurality of slot portions arranged at equal intervals in the circumferential direction.
  • the stator windings 402 are inserted into the slot portions.
  • the stator windings 402 of different phases are insulated from one another.
  • the stator core 401 and the stator windings 402 are insulated from one another.
  • FIG. 3 is a sectional view for illustrating main parts of the stator 4 of FIG. 2 .
  • the stator core 401 includes a plurality of core blocks 403 .
  • the number of the core blocks 403 is forty-eight.
  • the plurality of core blocks 403 are arranged in the circumferential direction.
  • the core blocks 403 each include a plurality of electromagnetic steel sheets laminated in the axial direction. The number of the electromagnetic steel sheets is the set number.
  • the core blocks 403 each include a core back portion 404 and a tooth portion 405 .
  • the core back portion 404 has an arc-shaped cross section.
  • the tooth portion 405 extends from a radially inner surface of the core back portion 404 toward the radially inner side.
  • distal end portions of the tooth portions 405 are oriented toward the radially inner side, and circumferential side surfaces of the core back portions 404 adjacent to each other in the circumferential direction are held in abutment against each other so that the forty-eight core back portions 404 are integrated.
  • the slot portions 406 are each formed by core blocks 403 adjacent to each other in the circumferential direction.
  • the slot portions 406 are arranged so as to open toward an inner side in the circumferential direction.
  • the plurality of slot portions 406 are arranged at an equiangular pitch in the circumferential direction.
  • the stator windings 402 each have a linear portion 407 having a rectangular cross section. A plurality of linear portions 407 are arranged in each of the slot portions 406 .
  • the stator 4 further includes a plurality of insulating sheets 408 provided in the slot portions 406 , respectively. The insulating sheets 408 are each provided between the stator core 401 and the linear portions 407 . The insulating sheets 408 are configured to insulate the stator core 401 and the stator windings 402 from one another.
  • FIG. 4 is a view for illustrating a radially inner portion of the stator 4 of FIG. 3 as viewed toward the radially outer side.
  • the stator windings 402 each include a lead wire 409 .
  • the lead wire 409 includes a conductor 410 and an insulating film 411 provided on side surfaces of the conductor 410 .
  • the conductor 410 is made of oxygen-free copper or oxygen-containing copper.
  • the linear portions 407 are arranged so as to extend in the axial direction.
  • the stator windings 402 each include oblique side portions 412 and a top portion 413 .
  • the oblique side portions 412 are provided at both end portions of the linear portions 407 in the axial direction, and are provided so as to incline with respect to the axial direction.
  • the top portion 413 connects adjacent oblique side portions 412 .
  • Both end portions of the insulating sheet 408 in the axial direction are arranged so as to extend toward the outer side in the axial direction with respect to the both end portions of the stator core 401 in the axial direction.
  • the insulating sheet 408 projects from the stator core 401 toward the outer side in the axial direction.
  • the stator windings 402 each include a terminal portion 414 and a joining portion 415 .
  • the terminal portion 414 is provided at the oblique side portion 412 located on one side in the axial direction with respect to the linear portion 407 , and extends in the axial direction.
  • the joining portion 415 is configured to join adjacent terminal portions 414 to each other.
  • the linear portions 407 , the oblique side portions 412 , the top portion 413 , and the terminal portion 414 are each formed of the lead wire 409 .
  • the terminal portion 414 is connected to an end portion of the oblique side portion 412 on a side opposite to the linear portion 407 side.
  • the terminal portion 414 is provided so as to extend from the end portion of the oblique side portion 412 toward the outer side in the axial direction.
  • the joining portion 415 is configured to join the terminal portions 414 to each other, which are connected through intermediation of oblique side portions 412 to linear portions 407 inserted into slot portions 406 adjacent to each other in the circumferential direction.
  • the terminal portions 414 joined to each other are arranged in the radial direction.
  • the joining portion 415 is located between the terminal portions 414 joined to each other.
  • FIG. 5 is a perspective view for illustrating the terminal portion 414 of FIG. 4 .
  • the terminal portion 414 has the conductor 410 partially exposed thereat.
  • the terminal portion 414 is a distal end portion of the lead wire 409 .
  • the terminal portion 414 includes a conductor exposure portion 416 and an insulating film remainder portion 417 .
  • the conductor exposure portion 416 has the conductor 410 exposed thereat.
  • the insulating film remainder portion 417 is provided at a portion of the terminal portion 414 excluding the conductor exposure portion 416 , and has the conductor 410 covered with the insulating film 411 .
  • the conductor exposure portion 416 includes a distal end surface 418 , a chamfered portion 419 , a planar portion 420 , and a step portion 421 .
  • the planar portion 420 is provided on a root side with respect to the chamfered portion 419 .
  • the step portion 421 is provided on a root side with respect to the planar portion 420 .
  • the root side corresponds to an inner side in the axial direction.
  • the chamfered portions 419 of the conductor exposure portions 416 which are provided at portions of the terminal portions 414 facing each other, are formed so as to separate away from each other as extending toward the distal end side.
  • the planar portions 420 of the conductor exposure portions 416 which are provided at portions of the terminal portions 414 facing each other, are opposed to each other.
  • the step portion 421 is oriented toward the distal end side.
  • the distal end side corresponds to an outer side in the axial direction.
  • the insulating film remainder portion 417 includes portions oriented in a width direction A of the lead wire 409 and a portion on a side opposite to the conductor exposure portion 416 of the lead wire 409 in a depth direction B.
  • the width direction A corresponds to a width direction of the lead wire 409 when viewed in a direction perpendicular to the planar portion 420 .
  • the depth direction B corresponds to the direction perpendicular to the planar portion 420 and corresponds to an opposing direction in which the planar portions 420 are opposed to each other.
  • the portions of the conductor 410 oriented in the width direction A are covered with the insulating film 411 , and the portion of the conductor 410 oriented toward the side opposite to the conductor exposure portion 416 in the depth direction B is covered with the insulating film 411 .
  • FIG. 6 is a view for illustrating a state in which two terminal portions 414 are joined to each other through laser radiation.
  • FIG. 7 is a plan view for illustrating the two terminal portions 414 of FIG. 6 .
  • the conductor exposure portions 416 are arranged at opposing portions of the two terminal portions 414 .
  • a joining member 422 is provided between the planar portions 420 of the conductor exposure portions 416 opposed to each other.
  • a melting point of the joining member 422 is lower than a melting point of the conductor 410 .
  • a production device 7 configured to produce the stator windings 402 includes a laser head 701 and chuck portions 702 .
  • the laser head 701 emits a laser light 703 .
  • the chuck portions 702 are arranged so as to be opposed to portions of the terminal portions 414 on sides opposite to the conductor exposure portions 416 in the depth direction B.
  • the chuck portions 702 pressurizes and holds the two terminal portions 414 and the joining member 422 in the depth direction B. In other words, under a state in which the joining member 422 is sandwiched between the two terminal portions 414 in the depth direction B, the chuck portions 702 pressurizes and holds the two terminal portions 414 in the depth direction B.
  • the depth direction B is a direction in which the two terminal portions 414 approach each other.
  • the laser light 703 emitted from the laser head 701 has a condensing property.
  • the two chamfered portions 419 of the terminal portions 414 and the joining member 422 are irradiated with the laser light. In such a manner, the chamfered portions 419 and the joining member 422 are heated.
  • FIG. 8 is a perspective view for illustrating the two terminal portions 414 joined to each other.
  • FIG. 9 is a sectional view for illustrating main parts of the stator 4 including the two terminal portions 414 joined to each other.
  • the joining portion 415 is formed between the two terminal portions 414 .
  • the joining portion 415 is connected to the chamfered portions 419 so that the joining portion 415 is provided over the chamfered portions 419 .
  • the two terminal portions 414 are joined to each other so that the conductors 410 of the two terminal portions 414 are electrically connected to each other.
  • the conductors 410 of the two terminal portions 414 are electrically connected to each other by brazing.
  • the joining portion 415 is an overlay alloy layer formed of alloys of the joining member 422 and the conductors 410 .
  • the joining portion 415 is formed through the brazing through use of the joining member 422 .
  • the joining member 422 which has not been melted is located between the planar portions 420 of the two terminal portions 414 .
  • An axial height position of the terminal portions 414 joined to each other with respect to the stator core 401 is set to a position at which a creepage distance and a clearance distance are secured between the terminal portion 414 and the top portion 413 of the stator winding 402 adjacent to the terminal portion 414 in the radial direction. With this, phase-to-phase insulation between the top portion 413 and the terminal portions 414 as well as the joining portion 415 is assured.
  • a gap 423 is defined between portions of the two lead wires 409 , which are provided on the root side with respect to the joining portion 415 and have the conductors 410 covered with the insulating film 411 .
  • FIG. 10 is a flowchart for illustrating a manufacturing method for the stator winding 402 of the rotating electric machine 1 according to the first embodiment of the present invention.
  • Step S 101 a pressurizing/holding step is performed.
  • the joining member 422 is provided between the conductor exposure portions 416 of the two terminal portions 414 , and the two terminal portions 414 are pressurized and held in the direction in which the two terminal portions 414 approach each other.
  • Step S 102 an overlaying step is performed.
  • the joining member 422 is irradiated with the laser light 703 , thereby forming the joining portion 415 at the conductor exposure portions 416 .
  • the two terminal portions 414 are joined to each other, and the conductors 410 of the two terminal portions 414 are electrically connected to each other. Then, the procedure for manufacturing the stator winding 402 is terminated.
  • a portion of the insulating film 411 in the insulating film remainder portion 417 is provided in a periphery of the joining portion 415 .
  • a dimension of the terminal portion 414 in the axial direction can be reduced.
  • a dimension of the stator winding 402 in the axial direction can be reduced.
  • the rotating electric machine 1 can be downsized.
  • the amount of use of the conductor 410 for the stator winding 402 can be reduced. As a result, the rotating electric machine 1 can be reduced in cost.
  • the joining portion 415 is an overlay alloy layer formed of alloys of the conductors 410 and the joining member 422 having a melting point lower than a melting point of the conductors 410 of the terminal portions 414 .
  • the joining portion 415 is provided over the chamfered portions 419 of the conductor exposure portions 416 facing each other.
  • the conductor exposure portion 416 includes the planar portion 420 and the step portion 421 .
  • the joining member 422 can be stably provided between the two terminal portions 414 .
  • the gap 423 is defined between portions of the two lead wires 409 adjacent to the root side with respect to the joining portion 415 .
  • the chamfered portions 419 are irradiated with the laser light 703 having the condensing property. With this, irradiation of the insulating film 411 with the laser light 703 is prevented. As a result, damage on the insulating film 411 can be reduced.
  • the chamfered portions 419 are irradiated with the laser light 703 .
  • multiple reflection of the laser light 703 occurs between the chamfered portions 419 and the joining member 422 .
  • the chamfered portions 419 and the joining member 422 are irradiated with the reflected laser light 703 a plurality of times.
  • output of the laser head 701 emitting the laser light 703 can be reduced.
  • the cost of the production device 7 configured to produce the stator windings 402 can be reduced.
  • the rotating electric machine 1 in which the stator windings 402 , which are formed of the plurality of lead wires 409 each having a hexagonal shape and are wound around the tooth portions 405 , are arranged in the circumferential direction.
  • the present invention is not limited to such a configuration.
  • the rotating electric machine 1 may have a configuration in which the stator windings 402 , which are formed of corrugated lead wires or U-shaped lead wires and are wound around the tooth portions 405 , may be arranged in the circumferential direction.
  • the joining member 422 is irradiated with the laser light 703 .
  • the present invention is not limited to such a configuration.
  • the joining member 422 may be irradiated with an electron beam having a condensing property.
  • FIG. 11 is a front view for illustrating main parts of a stator winding for a rotating electric machine according to a second embodiment of the present invention.
  • the two terminal portions 414 , the joining portion 415 , and the joining member 422 are illustrated.
  • the chamfered portions 419 each have a curved shape formed such that a center portion of the chamfered portion 419 in the height direction projects toward the joining portion 415 side.
  • Other configurations are the same as those of the first embodiment.
  • the chamfered portions 419 each have a curved shape formed such that a center portion of the chamfered portion 419 in the height direction projects toward the joining portion 415 side.
  • an angle formed between the root-side portion of the chamfered portion 419 and the joining member 422 can be reduced.
  • the multiple reflection of the laser light 703 is more likely to occur between the chamfered portion 419 and the joining member 422 .
  • output of the laser head 701 emitting the laser light 703 can be reduced, and the cost of the production device 7 configured to produce the stator windings 402 can be reduced.
  • FIG. 12 is a perspective view for illustrating a terminal portion of a stator winding for a rotating electric machine according to a third embodiment of the present invention.
  • FIG. 13 is a front view for illustrating the two terminal portions joined to each other.
  • the terminal portions 414 each include chamfered portion side surface conductor exposure portions 424 , which are provided at portions adjacent to the chamfered portion 419 in the depth direction B when viewed in the width direction A and have the conductor 410 exposed thereat.
  • portions of the insulating film 411 adjacent to the chamfered portion 419 in the depth direction B when viewed in the width direction A are removed from the conductor 410 .
  • Other configurations are the same as those of the first embodiment or the second embodiment.
  • the terminal portion 414 includes the chamfered portion side surface conductor exposure portion 424 , which are provided at portions adjacent to the chamfered portion 419 in the depth direction B when viewed in the width direction A and have the conductor 410 exposed thereat. With this, damage on the insulating film 411 caused by application of heat to the chamfered portion 419 can be prevented.
  • the terminal portion 414 may include axial end portion side surface conductor exposure portions 425 at which portions of the insulating film 411 adjacent to the distal end surface 418 in the axial direction are removed from the conductor 410 .
  • FIG. 14 and FIG. 15 the terminal portion 414 may include axial end portion side surface conductor exposure portions 425 at which portions of the insulating film 411 adjacent to the distal end surface 418 in the axial direction are removed from the conductor 410 .
  • the terminal portion 414 may include planar portion side surface conductor exposure portions 426 at which portions of the insulating film 411 adjacent to the planar portion 420 in the depth direction B when viewed in the width direction A are removed from the conductor 410 . In those cases, damage on the insulating film 411 can be further prevented.
  • the side surface conductor exposure portion includes the chamfered portion side surface conductor exposure portions 424 , the axial end portion side surface conductor exposure portions 425 , and the planar portion side surface conductor exposure portions 426 .
  • FIG. 16 is a perspective view for illustrating main parts of the stator winding 402 for the rotating electric machine 1 according to a fourth embodiment of the present invention.
  • FIG. 17 is a front view for illustrating main parts of the stator winding 402 of FIG. 16 .
  • Three terminal portions 414 are arranged in the radial direction. Two terminal portions 414 among the three terminal portions 414 , which are arranged at both end portions in the arrangement direction, each include one conductor exposure portion 416 similarly to the first embodiment.
  • One terminal portion 414 among the three terminal portions 414 which is arranged at a center portion in the arrangement direction, includes two conductor exposure portions 416 .
  • the two terminal portions 414 among the three terminal portions 414 which are arranged at the both end portions in the arrangement direction, are referred to as “outer terminal portion 414 A”.
  • the one terminal portion 414 among the three terminal portions 414 which is arranged at the center portion in the arrangement direction, is referred to as “center terminal portion 414 B”.
  • One of the two conductor exposure portions 416 of the center terminal portion 414 B is provided at a portion of the center terminal portion 414 B facing the conductor exposure portion 416 of the outer terminal portion 414 A arranged at one end portion in the arrangement direction.
  • Another one of the two conductor exposure portions 416 of the center terminal portion 414 B is provided at a portion of the center terminal portion 414 B facing the conductor exposure portion 416 of the outer terminal portion 414 A arranged at another end portion in the arrangement direction.
  • One joining portion 415 is provided between the chamfered portion 419 of each of the two outer terminal portions 414 A and the chamfered portion 419 of the center terminal portion 414 B.
  • Other configurations are the same as those of any one of the first to third embodiments.
  • the lead wires 409 of the three terminal portions 414 are joined to one another by the two joining portions 415 , and the conductors 410 are electrically connected to one another by the plurality of joining portions 415 . With this, a joining operation can be reduced.
  • FIG. 18 is a perspective view for illustrating a terminal portion of a stator winding for a rotating electric machine according to a fifth embodiment of the present invention.
  • FIG. 19 is a perspective view for illustrating a state in which a joining member is mounted to the terminal portion of FIG. 18 .
  • FIG. 20 is a front view for illustrating the terminal portion and the joining member of FIG. 19 .
  • FIG. 21 is a plan view for illustrating a state in which two terminal portions of FIG. 18 are held in press contact with each other.
  • the lead wires 409 further includes a pair of insulating film step portions 427 , which are provided on both sides with respect to the planar portion 420 in the width direction A when viewed in a direction perpendicular to the planar portion 420 and have the conductor 410 covered with the insulating film 411 .
  • a joining member 422 is sandwiched between the pair of insulating film step portions 427 in the width direction A. A position of the joining member 422 with respect to the terminal portion 414 in the width direction A is restricted by the pair of insulating film step portions 427 .
  • Other configurations are the same as those of any one of the first to fourth embodiments.
  • the lead wires 409 each further include the pair of insulating film step portions 427 , which are provided on both sides with respect to the planar portion 420 in the width direction A and have the conductor 410 covered with the insulating film 411 .
  • arrangement of the joining member 422 biased toward one side in the width direction A is prevented.
  • quality of the joining portion 415 configured to join the two terminal portions 414 can be stabilized.
  • the lead wire 409 may have a configuration in which the insulating film step portion 427 is provided only on one side with respect to the planar portion 420 in the width direction A when viewed in the direction perpendicular to the planar portion 420 .
  • the joining member 422 is arranged between the insulating film step portion 427 of one terminal portion 414 of the two terminal portions 414 and the insulating film step portion 427 of another the terminal portion 414 . Even in this case, the arrangement of the joining member 422 biased with respect to the terminal portion 414 in the width direction A is prevented.
  • FIG. 24 is a perspective view for illustrating a terminal portion of a stator winding for a rotating electric machine according to a sixth embodiment of the present invention.
  • FIG. 25 is a plan view for illustrating two terminal portions joined to each other.
  • FIG. 26 is a sectional view taken along the line XXVI-XXVI of FIG. 25 as viewed in the direction indicated by the arrows.
  • FIG. 27 is a sectional view for illustrating main parts of the stator 4 including two terminal portions 414 joined to each other.
  • the terminal portions 414 are arranged so as to extend in the direction perpendicular to the axial direction. In this example, the terminal portions 414 are arranged so as to extend in the circumferential direction.
  • the two terminal portions 414 are arranged so as to extend in directions opposite to each other.
  • the two terminal portions 414 are arranged so as to be adjacent to each other in the radial direction.
  • Other configurations are the same as those of any one of the first to fifth embodiments.
  • the plurality of terminal portions 414 are arranged so as to extend in the direction perpendicular to the axial direction of the rotating electric machine 1 . With this, regions in which the two terminal portions 414 are adjacent to each other can be increased. As a result, the joining strength of the two terminal portions 414 can be improved.

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Windings For Motors And Generators (AREA)
  • Insulation, Fastening Of Motor, Generator Windings (AREA)
  • Manufacture Of Motors, Generators (AREA)

Abstract

A stator winding for a rotating electric machine includes: a plurality of lead wires each including a conductor and an insulating film provided on side surfaces of the conductor; and a joining portion configured to join terminal portions of the plurality of lead wires to each other. The plurality of lead wires each includes: a conductor exposure portion provided at a portion of the terminal portion at which the terminal portions of the plurality of lead wires face each other, has the conductor exposed thereat, and has the joining portion connected thereto; and an insulating film remainder portion, provided at a portion of the terminal portion of the lead wire excluding the conductor exposure portion, and has the conductor covered with the insulating film, and a portion of the insulating film in the insulating film remainder portion is provided in a periphery of the joining portion.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention
The present invention relates to a stator winding for a rotating electric machine in which conductors of a plurality of lead wires are electrically connected to each other by joining portions, and to a manufacturing method therefor.
2. Description of the Related Art
There has hitherto been known a stator winding for a rotating electric machine, which includes a plurality of lead wires and joining portions. The plurality of lead wires each include a conductor and an insulating film provided on side surfaces of the conductor. The joining portions are configured to electrically connect the conductors of the plurality of lead wires. Terminal portions of the plurality of lead wires each have the conductor exposed therefrom to form a conductor exposure portion having the joining portion connected thereto (for example, see Japanese Patent No. 6448664).
SUMMARY OF THE INVENTION
However, the entirety of the terminal portion of the lead wire form the conductor exposure portion. As a result, there is a problem in that a dimension of the stator winding in an axial direction of the rotating electric machine is large.
The present invention has been made to solve the problem described above, has an object to provide a stator winding for a rotating electric machine which is capable of reducing a dimension of the stator winding in an axial direction of a rotating electric machine, and a manufacturing method therefor.
According to one embodiment of the present invention, provided is a stator winding for a rotating electric machine, including: a plurality of lead wires each including a conductor and an insulating film provided on side surfaces of the conductor; and a joining portion configured to join terminal portions of the plurality of lead wires to each other, to thereby electrically connect the conductors of the plurality of lead wires, wherein the plurality of lead wires each include: a conductor exposure portion, which is provided at a portion of the terminal portion at which the terminal portions of the plurality of lead wires face each other, has the conductor exposed thereat, and has the joining portion connected thereto; and an insulating film remainder portion, which is provided at a portion of the terminal portion of the lead wire excluding the conductor exposure portion, and has the conductor covered with the insulating film, and wherein a portion of the insulating film in the insulating film remainder portion is provided in a periphery of the joining portion.
According to the stator winding for a rotating electric machine of the present invention, it is possible to reduce a dimension of the stator winding in an axial direction of a rotating electric machine, and a manufacturing method therefor.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial sectional view for illustrating a rotating electric machine according to a first embodiment of the present invention.
FIG. 2 is a perspective view for illustrating a stator of FIG. 1.
FIG. 3 is a sectional view for illustrating main parts of the stator of FIG. 2.
FIG. 4 is a view for illustrating a radially inner portion of the stator of FIG. 3 as viewed toward a radially outer side.
FIG. 5 is a perspective view for illustrating a terminal portion of FIG. 4.
FIG. 6 is a view for illustrating a state in which two terminal portions are joined to each other through laser radiation.
FIG. 7 is a plan view for illustrating the two terminal portions of FIG. 6.
FIG. 8 is a perspective view for illustrating the two terminal portions joined to each other.
FIG. 9 is a sectional view for illustrating main parts of the stator including the two terminal portions joined to each other.
FIG. 10 is a flowchart for illustrating a manufacturing method for a stator winding for a rotating electric machine according to the first embodiment of the present invention.
FIG. 11 is a front view for illustrating main parts of a stator winding for a rotating electric machine according to a second embodiment of the present invention.
FIG. 12 is a perspective view for illustrating a terminal portion of a stator winding for a rotating electric machine according to a third embodiment of the present invention.
FIG. 13 is a front view for illustrating two terminal portions joined to each other.
FIG. 14 is a perspective view for illustrating a modification example of the terminal portion.
FIG. 15 is a front view for illustrating a modification example of two terminal portions joined to each other.
FIG. 16 is a perspective view for illustrating main parts of a stator winding for a rotating electric machine according to a fourth embodiment of the present invention.
FIG. 17 is a front view for illustrating main parts of the stator winding of FIG. 16.
FIG. 18 is a perspective view for illustrating a terminal portion of a stator winding for a rotating electric machine according to a fifth embodiment of the present invention.
FIG. 19 is a perspective view for illustrating a state in which a joining member is mounted to the terminal portion of FIG. 18.
FIG. 20 is a front view for illustrating the terminal portion and the joining member of FIG. 19.
FIG. 21 is a plan view for illustrating two terminal portions held in press contact with each other.
FIG. 22 is a perspective view for illustrating a modification example of the terminal portion.
FIG. 23 is a plan view for illustrating a modification example of the two terminal portions held in press contact with each other.
FIG. 24 is a perspective view for illustrating a terminal portion of a stator winding for a rotating electric machine according to a sixth embodiment of the present invention.
FIG. 25 is a plan view for illustrating two terminal portions joined to each other.
FIG. 26 is a sectional view taken along the line XXVI-XXVI of FIG. 25 as viewed in the direction indicated by the arrows.
FIG. 27 is a sectional view for illustrating main parts of a stator including two terminal portions joined to each other.
 DESCRIPTION OF THE EMBODIMENTS First Embodiment
FIG. 1 is a partial sectional view for illustrating a rotating electric machine according to a first embodiment of the present invention. A rotating electric machine 1 includes a shaft 2 configured to transmit torque to an outside. In this example, an axial direction corresponds to a direction along the shaft 2, a radial direction corresponds to a radial direction with the shaft 2 being a center, and a circumferential direction corresponds to a circumferential direction with the shaft 2 being a center. In FIG. 1, the rotating electric machine 1 is illustrated in sectional view on a right side with respect to a plane passing through the center of the shaft 2 and extending along the shaft 2, and is illustrated in front view on a left side.
The rotating electric machine 1 includes a housing 3, a stator 4, a rotor 5, and a plurality of bearings 6. The stator 4 is supported on the housing 3, and is configured to generate a rotational magnetic field. The rotor 5 is provided on a radially inner side with respect to the stator 4. The plurality of bearings 6 are supported on the housing 3, and are configured to rotatably support the shaft 2.
The rotor 5 is supported on the housing 3 through intermediation of the shaft 2 and the bearings 6. The rotor 5 rotates relative to the stator 4 in the circumferential direction. A gap is defined between the stator 4 and the rotor 5 in the radial direction. The rotor 5 is fixed to the shaft 2, and includes a rotor core 501 and a plurality of permanent magnets 502. The rotor core 501 allows magnetic fluxes to pass therethrough. The plurality of permanent magnets 502 are embedded in the rotor core 501.
FIG. 2 is a perspective view for illustrating the stator 4 of FIG. 1. The stator 4 includes a stator core 401 and a plurality of stator windings 402. The stator core 401 has an annular shape. The plurality of stator windings 402 are supported on the stator core 401, and are configured to generate a magnetic field through feeding of a current therethrough. The stator core 401 has a plurality of slot portions arranged at equal intervals in the circumferential direction. The stator windings 402 are inserted into the slot portions. The stator windings 402 of different phases are insulated from one another. The stator core 401 and the stator windings 402 are insulated from one another.
FIG. 3 is a sectional view for illustrating main parts of the stator 4 of FIG. 2. The stator core 401 includes a plurality of core blocks 403. In this example, the number of the core blocks 403 is forty-eight. The plurality of core blocks 403 are arranged in the circumferential direction. The core blocks 403 each include a plurality of electromagnetic steel sheets laminated in the axial direction. The number of the electromagnetic steel sheets is the set number.
The core blocks 403 each include a core back portion 404 and a tooth portion 405. The core back portion 404 has an arc-shaped cross section. The tooth portion 405 extends from a radially inner surface of the core back portion 404 toward the radially inner side.
In the stator core 401, distal end portions of the tooth portions 405 are oriented toward the radially inner side, and circumferential side surfaces of the core back portions 404 adjacent to each other in the circumferential direction are held in abutment against each other so that the forty-eight core back portions 404 are integrated. The slot portions 406 are each formed by core blocks 403 adjacent to each other in the circumferential direction. The slot portions 406 are arranged so as to open toward an inner side in the circumferential direction. The plurality of slot portions 406 are arranged at an equiangular pitch in the circumferential direction.
The stator windings 402 each have a linear portion 407 having a rectangular cross section. A plurality of linear portions 407 are arranged in each of the slot portions 406. The stator 4 further includes a plurality of insulating sheets 408 provided in the slot portions 406, respectively. The insulating sheets 408 are each provided between the stator core 401 and the linear portions 407. The insulating sheets 408 are configured to insulate the stator core 401 and the stator windings 402 from one another.
FIG. 4 is a view for illustrating a radially inner portion of the stator 4 of FIG. 3 as viewed toward the radially outer side. The stator windings 402 each include a lead wire 409. The lead wire 409 includes a conductor 410 and an insulating film 411 provided on side surfaces of the conductor 410. The conductor 410 is made of oxygen-free copper or oxygen-containing copper.
The linear portions 407 are arranged so as to extend in the axial direction. The stator windings 402 each include oblique side portions 412 and a top portion 413. The oblique side portions 412 are provided at both end portions of the linear portions 407 in the axial direction, and are provided so as to incline with respect to the axial direction. The top portion 413 connects adjacent oblique side portions 412.
Both end portions of the insulating sheet 408 in the axial direction are arranged so as to extend toward the outer side in the axial direction with respect to the both end portions of the stator core 401 in the axial direction. In other words, the insulating sheet 408 projects from the stator core 401 toward the outer side in the axial direction. With this configuration, both surfaces of the stator core 401 in the axial direction are insulated from the stator windings 402.
The stator windings 402 each include a terminal portion 414 and a joining portion 415. The terminal portion 414 is provided at the oblique side portion 412 located on one side in the axial direction with respect to the linear portion 407, and extends in the axial direction. The joining portion 415 is configured to join adjacent terminal portions 414 to each other. The linear portions 407, the oblique side portions 412, the top portion 413, and the terminal portion 414 are each formed of the lead wire 409. The terminal portion 414 is connected to an end portion of the oblique side portion 412 on a side opposite to the linear portion 407 side. The terminal portion 414 is provided so as to extend from the end portion of the oblique side portion 412 toward the outer side in the axial direction. The joining portion 415 is configured to join the terminal portions 414 to each other, which are connected through intermediation of oblique side portions 412 to linear portions 407 inserted into slot portions 406 adjacent to each other in the circumferential direction. The terminal portions 414 joined to each other are arranged in the radial direction. The joining portion 415 is located between the terminal portions 414 joined to each other.
FIG. 5 is a perspective view for illustrating the terminal portion 414 of FIG. 4. The terminal portion 414 has the conductor 410 partially exposed thereat. The terminal portion 414 is a distal end portion of the lead wire 409. The terminal portion 414 includes a conductor exposure portion 416 and an insulating film remainder portion 417. The conductor exposure portion 416 has the conductor 410 exposed thereat. The insulating film remainder portion 417 is provided at a portion of the terminal portion 414 excluding the conductor exposure portion 416, and has the conductor 410 covered with the insulating film 411.
The conductor exposure portion 416 includes a distal end surface 418, a chamfered portion 419, a planar portion 420, and a step portion 421. The planar portion 420 is provided on a root side with respect to the chamfered portion 419. The step portion 421 is provided on a root side with respect to the planar portion 420. In this example, the root side corresponds to an inner side in the axial direction. The chamfered portions 419 of the conductor exposure portions 416, which are provided at portions of the terminal portions 414 facing each other, are formed so as to separate away from each other as extending toward the distal end side. The planar portions 420 of the conductor exposure portions 416, which are provided at portions of the terminal portions 414 facing each other, are opposed to each other. The step portion 421 is oriented toward the distal end side. In this example, the distal end side corresponds to an outer side in the axial direction.
The insulating film remainder portion 417 includes portions oriented in a width direction A of the lead wire 409 and a portion on a side opposite to the conductor exposure portion 416 of the lead wire 409 in a depth direction B. In this example, the width direction A corresponds to a width direction of the lead wire 409 when viewed in a direction perpendicular to the planar portion 420. Moreover, in this example, the depth direction B corresponds to the direction perpendicular to the planar portion 420 and corresponds to an opposing direction in which the planar portions 420 are opposed to each other. The portions of the conductor 410 oriented in the width direction A are covered with the insulating film 411, and the portion of the conductor 410 oriented toward the side opposite to the conductor exposure portion 416 in the depth direction B is covered with the insulating film 411.
FIG. 6 is a view for illustrating a state in which two terminal portions 414 are joined to each other through laser radiation. FIG. 7 is a plan view for illustrating the two terminal portions 414 of FIG. 6. The conductor exposure portions 416 are arranged at opposing portions of the two terminal portions 414. A joining member 422 is provided between the planar portions 420 of the conductor exposure portions 416 opposed to each other. A melting point of the joining member 422 is lower than a melting point of the conductor 410.
A production device 7 configured to produce the stator windings 402 includes a laser head 701 and chuck portions 702. The laser head 701 emits a laser light 703. The chuck portions 702 are arranged so as to be opposed to portions of the terminal portions 414 on sides opposite to the conductor exposure portions 416 in the depth direction B. The chuck portions 702 pressurizes and holds the two terminal portions 414 and the joining member 422 in the depth direction B. In other words, under a state in which the joining member 422 is sandwiched between the two terminal portions 414 in the depth direction B, the chuck portions 702 pressurizes and holds the two terminal portions 414 in the depth direction B. The depth direction B is a direction in which the two terminal portions 414 approach each other.
The laser light 703 emitted from the laser head 701 has a condensing property. The two chamfered portions 419 of the terminal portions 414 and the joining member 422 are irradiated with the laser light. In such a manner, the chamfered portions 419 and the joining member 422 are heated.
FIG. 8 is a perspective view for illustrating the two terminal portions 414 joined to each other. FIG. 9 is a sectional view for illustrating main parts of the stator 4 including the two terminal portions 414 joined to each other. Through the heating of the chamfered portions 419 and the joining member 422, the joining portion 415 is formed between the two terminal portions 414. As a result, the joining portion 415 is connected to the chamfered portions 419 so that the joining portion 415 is provided over the chamfered portions 419. Moreover, through the formation of the joining portion 415 between the two terminal portions 414, the two terminal portions 414 are joined to each other so that the conductors 410 of the two terminal portions 414 are electrically connected to each other. The conductors 410 of the two terminal portions 414 are electrically connected to each other by brazing. The joining portion 415 is an overlay alloy layer formed of alloys of the joining member 422 and the conductors 410.
With the two terminal portions 414 and the joining member 422 being pressurized and held by the chuck portions 702, formation of a gap between the terminal portions 414 and the joining member 422 is prevented. Such a configuration prevents the phenomenon in which the laser light 703 having leaked out through the gap between the terminal portions 414 and the joining member 422 strikes a portion of the insulating film 411 located on the root side with respect to the planar portion 420. As a result, damage on the portion of the insulating film 411 located on the root side with respect to the planar portion 420 is prevented.
The joining portion 415 is formed through the brazing through use of the joining member 422. The joining member 422 which has not been melted is located between the planar portions 420 of the two terminal portions 414. An axial height position of the terminal portions 414 joined to each other with respect to the stator core 401 is set to a position at which a creepage distance and a clearance distance are secured between the terminal portion 414 and the top portion 413 of the stator winding 402 adjacent to the terminal portion 414 in the radial direction. With this, phase-to-phase insulation between the top portion 413 and the terminal portions 414 as well as the joining portion 415 is assured.
A gap 423 is defined between portions of the two lead wires 409, which are provided on the root side with respect to the joining portion 415 and have the conductors 410 covered with the insulating film 411. With this configuration, when the two terminal portions 414 are joined to each other, transfer of heat generated in one terminal portion 414 to another terminal portion 414 through the insulating film 411 is prevented. Accordingly, damage on the insulating film 411 is reduced.
Next, description is made of a manufacturing method for the stator winding 402 with the two terminal portions 414 joined to each other. FIG. 10 is a flowchart for illustrating a manufacturing method for the stator winding 402 of the rotating electric machine 1 according to the first embodiment of the present invention. First, in Step S101, a pressurizing/holding step is performed. In the pressurizing/holding step, the joining member 422 is provided between the conductor exposure portions 416 of the two terminal portions 414, and the two terminal portions 414 are pressurized and held in the direction in which the two terminal portions 414 approach each other.
After that, in Step S102, an overlaying step is performed. In the overlaying step, the joining member 422 is irradiated with the laser light 703, thereby forming the joining portion 415 at the conductor exposure portions 416. As a result, the two terminal portions 414 are joined to each other, and the conductors 410 of the two terminal portions 414 are electrically connected to each other. Then, the procedure for manufacturing the stator winding 402 is terminated.
As described above, according to the stator winding 402 for the rotating electric machine 1 of the first embodiment of the present invention, a portion of the insulating film 411 in the insulating film remainder portion 417 is provided in a periphery of the joining portion 415. With this, a dimension of the terminal portion 414 in the axial direction can be reduced. As a result, a dimension of the stator winding 402 in the axial direction can be reduced. Moreover, through the reduction of the dimension of the stator winding 402 in the axial direction, the rotating electric machine 1 can be downsized. Moreover, through the reduction of the dimension of the stator winding 402 in the axial direction, the amount of use of the conductor 410 for the stator winding 402 can be reduced. As a result, the rotating electric machine 1 can be reduced in cost.
Moreover, the joining portion 415 is an overlay alloy layer formed of alloys of the conductors 410 and the joining member 422 having a melting point lower than a melting point of the conductors 410 of the terminal portions 414. With this, the amount of heat applied to the terminal portions 414 by the laser light 703 can be reduced. As a result, damage on the insulating film 411 can be reduced.
Moreover, the joining portion 415 is provided over the chamfered portions 419 of the conductor exposure portions 416 facing each other. With this, the two terminal portions 414 can be joined, and the conductors 410 of the two terminal portions 414 can be electrically connected to each other.
Moreover, the conductor exposure portion 416 includes the planar portion 420 and the step portion 421. With this, the joining member 422 can be stably provided between the two terminal portions 414.
Moreover, the gap 423 is defined between portions of the two lead wires 409 adjacent to the root side with respect to the joining portion 415. With this, damage on the insulating film 411 provided at the portions of the plurality of lead wires 409 adjacent to the root side with respect to the joining portion 415 can be prevented.
Moreover, according to the manufacturing method for the stator winding 402 for the rotating electric machine 1 of the first embodiment of the present invention, the chamfered portions 419 are irradiated with the laser light 703 having the condensing property. With this, irradiation of the insulating film 411 with the laser light 703 is prevented. As a result, damage on the insulating film 411 can be reduced.
Moreover, the chamfered portions 419 are irradiated with the laser light 703. With this, multiple reflection of the laser light 703 occurs between the chamfered portions 419 and the joining member 422. With this, the chamfered portions 419 and the joining member 422 are irradiated with the reflected laser light 703 a plurality of times. Thus, output of the laser head 701 emitting the laser light 703 can be reduced. As a result, the cost of the production device 7 configured to produce the stator windings 402 can be reduced.
Moreover, it is not required that all of the insulating film 411 of the terminal portion 414 be removed. With this, the cost of the production device 7 configured to produce the stator windings 402 can be reduced.
In the first embodiment, description is made of the configuration of the rotating electric machine 1 in which the stator windings 402, which are formed of the plurality of lead wires 409 each having a hexagonal shape and are wound around the tooth portions 405, are arranged in the circumferential direction. However, the present invention is not limited to such a configuration. For example, the rotating electric machine 1 may have a configuration in which the stator windings 402, which are formed of corrugated lead wires or U-shaped lead wires and are wound around the tooth portions 405, may be arranged in the circumferential direction.
Moreover, in the first embodiment, description is made of the configuration in which the joining member 422 is irradiated with the laser light 703. However, the present invention is not limited to such a configuration. For example, the joining member 422 may be irradiated with an electron beam having a condensing property.
Second Embodiment
FIG. 11 is a front view for illustrating main parts of a stator winding for a rotating electric machine according to a second embodiment of the present invention. In FIG. 11, the two terminal portions 414, the joining portion 415, and the joining member 422 are illustrated. The chamfered portions 419 each have a curved shape formed such that a center portion of the chamfered portion 419 in the height direction projects toward the joining portion 415 side. Other configurations are the same as those of the first embodiment.
As described above, according to the stator winding 402 for the rotating electric machine 1 of the second embodiment of the present invention, the chamfered portions 419 each have a curved shape formed such that a center portion of the chamfered portion 419 in the height direction projects toward the joining portion 415 side. With this, an angle formed between the root-side portion of the chamfered portion 419 and the joining member 422 can be reduced. Thus, the multiple reflection of the laser light 703 is more likely to occur between the chamfered portion 419 and the joining member 422. As a result, output of the laser head 701 emitting the laser light 703 can be reduced, and the cost of the production device 7 configured to produce the stator windings 402 can be reduced.
Third Embodiment
FIG. 12 is a perspective view for illustrating a terminal portion of a stator winding for a rotating electric machine according to a third embodiment of the present invention. FIG. 13 is a front view for illustrating the two terminal portions joined to each other. The terminal portions 414 each include chamfered portion side surface conductor exposure portions 424, which are provided at portions adjacent to the chamfered portion 419 in the depth direction B when viewed in the width direction A and have the conductor 410 exposed thereat. In other words, portions of the insulating film 411 adjacent to the chamfered portion 419 in the depth direction B when viewed in the width direction A are removed from the conductor 410. Other configurations are the same as those of the first embodiment or the second embodiment.
As described above, according to the stator winding 402 for the rotating electric machine 1 of the third embodiment of the present invention, the terminal portion 414 includes the chamfered portion side surface conductor exposure portion 424, which are provided at portions adjacent to the chamfered portion 419 in the depth direction B when viewed in the width direction A and have the conductor 410 exposed thereat. With this, damage on the insulating film 411 caused by application of heat to the chamfered portion 419 can be prevented.
In the third embodiment, description is made of the configuration in which the insulating film 411 at the portions of the terminal portion 414 adjacent to each other in the depth direction B with respect to the chamfered portion 419 when viewed in the width direction A is removed from the conductor 410. However, the present invention is not limited to this configuration. As illustrated in FIG. 14 and FIG. 15, the terminal portion 414 may include axial end portion side surface conductor exposure portions 425 at which portions of the insulating film 411 adjacent to the distal end surface 418 in the axial direction are removed from the conductor 410. Moreover, as illustrated in FIG. 14 and FIG. 15, the terminal portion 414 may include planar portion side surface conductor exposure portions 426 at which portions of the insulating film 411 adjacent to the planar portion 420 in the depth direction B when viewed in the width direction A are removed from the conductor 410. In those cases, damage on the insulating film 411 can be further prevented. The side surface conductor exposure portion includes the chamfered portion side surface conductor exposure portions 424, the axial end portion side surface conductor exposure portions 425, and the planar portion side surface conductor exposure portions 426.
Fourth Embodiment
FIG. 16 is a perspective view for illustrating main parts of the stator winding 402 for the rotating electric machine 1 according to a fourth embodiment of the present invention. FIG. 17 is a front view for illustrating main parts of the stator winding 402 of FIG. 16. Three terminal portions 414 are arranged in the radial direction. Two terminal portions 414 among the three terminal portions 414, which are arranged at both end portions in the arrangement direction, each include one conductor exposure portion 416 similarly to the first embodiment. One terminal portion 414 among the three terminal portions 414, which is arranged at a center portion in the arrangement direction, includes two conductor exposure portions 416.
The two terminal portions 414 among the three terminal portions 414, which are arranged at the both end portions in the arrangement direction, are referred to as “outer terminal portion 414A”. The one terminal portion 414 among the three terminal portions 414, which is arranged at the center portion in the arrangement direction, is referred to as “center terminal portion 414B”. One of the two conductor exposure portions 416 of the center terminal portion 414B is provided at a portion of the center terminal portion 414B facing the conductor exposure portion 416 of the outer terminal portion 414A arranged at one end portion in the arrangement direction. Another one of the two conductor exposure portions 416 of the center terminal portion 414B is provided at a portion of the center terminal portion 414B facing the conductor exposure portion 416 of the outer terminal portion 414A arranged at another end portion in the arrangement direction. One joining portion 415 is provided between the chamfered portion 419 of each of the two outer terminal portions 414A and the chamfered portion 419 of the center terminal portion 414B. Other configurations are the same as those of any one of the first to third embodiments.
As described above, according to the stator winding 402 for the rotating electric machine 1 of the fourth embodiment of the present invention, the lead wires 409 of the three terminal portions 414 are joined to one another by the two joining portions 415, and the conductors 410 are electrically connected to one another by the plurality of joining portions 415. With this, a joining operation can be reduced.
In the fourth embodiment, description is made of the configuration in which the three terminal portions 414 are joined to one another by the joining portions 415, and the conductors 410 are electrically connected to one another by the joining portions 415. However, there may be adopted a configuration in which four or more terminal portions 414 are joined to one another by joining portions 415, and conductors 410 are electrically connected to one another by the joining portions 415.
Fifth Embodiment
FIG. 18 is a perspective view for illustrating a terminal portion of a stator winding for a rotating electric machine according to a fifth embodiment of the present invention. FIG. 19 is a perspective view for illustrating a state in which a joining member is mounted to the terminal portion of FIG. 18. FIG. 20 is a front view for illustrating the terminal portion and the joining member of FIG. 19. FIG. 21 is a plan view for illustrating a state in which two terminal portions of FIG. 18 are held in press contact with each other. The lead wires 409 further includes a pair of insulating film step portions 427, which are provided on both sides with respect to the planar portion 420 in the width direction A when viewed in a direction perpendicular to the planar portion 420 and have the conductor 410 covered with the insulating film 411. A joining member 422 is sandwiched between the pair of insulating film step portions 427 in the width direction A. A position of the joining member 422 with respect to the terminal portion 414 in the width direction A is restricted by the pair of insulating film step portions 427. Other configurations are the same as those of any one of the first to fourth embodiments.
As described above, according to the stator winding 402 for the rotating electric machine 1 of the fifth embodiment of the present invention, the lead wires 409 each further include the pair of insulating film step portions 427, which are provided on both sides with respect to the planar portion 420 in the width direction A and have the conductor 410 covered with the insulating film 411. With this, arrangement of the joining member 422 biased toward one side in the width direction A is prevented. Thus, quality of the joining portion 415 configured to join the two terminal portions 414 can be stabilized.
Moreover, in the fifth embodiment, description is made of the configuration in which the insulating film step portions 427 are provided on both sides with respect to the planar portion 420 in the width direction A when viewed in the direction perpendicular to the planar portion 420. However, as illustrated in FIG. 22 and FIG. 23, the lead wire 409 may have a configuration in which the insulating film step portion 427 is provided only on one side with respect to the planar portion 420 in the width direction A when viewed in the direction perpendicular to the planar portion 420. In this case, the joining member 422 is arranged between the insulating film step portion 427 of one terminal portion 414 of the two terminal portions 414 and the insulating film step portion 427 of another the terminal portion 414. Even in this case, the arrangement of the joining member 422 biased with respect to the terminal portion 414 in the width direction A is prevented.
Sixth Embodiment
FIG. 24 is a perspective view for illustrating a terminal portion of a stator winding for a rotating electric machine according to a sixth embodiment of the present invention. FIG. 25 is a plan view for illustrating two terminal portions joined to each other. FIG. 26 is a sectional view taken along the line XXVI-XXVI of FIG. 25 as viewed in the direction indicated by the arrows. FIG. 27 is a sectional view for illustrating main parts of the stator 4 including two terminal portions 414 joined to each other. The terminal portions 414 are arranged so as to extend in the direction perpendicular to the axial direction. In this example, the terminal portions 414 are arranged so as to extend in the circumferential direction. The two terminal portions 414 are arranged so as to extend in directions opposite to each other. The two terminal portions 414 are arranged so as to be adjacent to each other in the radial direction. Other configurations are the same as those of any one of the first to fifth embodiments.
As described above, according to the stator winding 402 for the rotating electric machine 1 of the sixth embodiment of the present invention, the plurality of terminal portions 414 are arranged so as to extend in the direction perpendicular to the axial direction of the rotating electric machine 1. With this, regions in which the two terminal portions 414 are adjacent to each other can be increased. As a result, the joining strength of the two terminal portions 414 can be improved.

Claims (8)

What is claimed is:
1. A stator winding for a rotating electric machine, comprising:
a plurality of lead wires each including a conductor and an insulating film provided on side surfaces of the conductor; and
a joining portion configured to join terminal portions of the plurality of lead wires to each other, to thereby electrically connect the conductors of the plurality of lead wires,
wherein the plurality of lead wires each include:
a conductor exposure portion, which is provided at a portion of the terminal portion at which the terminal portions of the plurality of lead wires face each other, has the conductor exposed thereat, and has the joining portion connected thereto; and
an insulating film remainder portion, which is provided at a portion of the terminal portion of the plurality of lead wires excluding the conductor exposure portion, and has the conductor covered with the insulating film, and
wherein a portion of the insulating film in the insulating film remainder portion is provided in a periphery of the joining portion,
wherein the conductor exposure portions provided at portions of the terminal portions facing each other include chamfered portions formed so as to separate away from each other as extending toward a distal end side,
wherein the joining portion is arranged over the chamfered portions of the conductor exposure portions facing each other,
wherein the conductor exposure portions provided at portions of the terminal portions facing each other include:
planar portions, which are provided on a root side with respect to the chamfered portions, and are opposed to each other, and
step portions, which are provided on a root side with respect to the planar portions, and are oriented toward a distal end side.
2. The stator winding for a rotating electric machine according to claim 1, wherein the joining portion includes an overlay alloy layer formed of alloys of the conductor and the joining member having a melting point lower than a melting point of the conductor.
3. The stator winding for a rotating electric machine according to claim 1, wherein the lead wires each include an insulating film step portion, which is provided on at least one side with respect to the planar portion in the width direction of the lead wire when viewed in a direction perpendicular to the planar portion, and has the conductor covered with the insulating film.
4. The stator winding for a rotating electric machine according to claim 1, wherein the lead wires each include a side surface conductor exposure portion, which is provided at a portion of the terminal portion adjacent to the conductor exposure portion when viewed in a width direction of the lead wire, and has the conductor exposed thereat.
5. The stator winding for a rotating electric machine according to claim 1,
wherein the terminal portions of three or more arranged wires are joined to one another by a plurality of joining portions, and
wherein the conductors of the lead wires are electrically connected to one another by the plurality of joining portions.
6. The stator winding for a rotating electric machine according to claim 1, wherein a gap is defined between portions of the plurality of lead wires adjacent to the root side with respect to the joining portions.
7. The stator winding for a rotating electric machine according to claim 1, wherein the terminal portions of the plurality of lead wires are arranged so as to extend in a direction perpendicular to the axial direction of the rotating electric machine.
8. A manufacturing method for a stator winding for a rotating electric machine, which is to be performed to manufacture the stator winding for a rotating electric machine of claim 1, the manufacturing method comprising:
a pressurizing/holding step of arranging a joining member between the conductor exposure portions of the plurality of lead wires and pressurizing and holding the plurality of lead wires in a direction in which the plurality of lead wires approach each other; and
an overlaying step of forming the joining portion at the conductor exposure portion by irradiating the joining member with a laser light or an electron beam.
US16/827,920 2019-04-10 2020-03-24 Stator winding for rotating electric machine, and manufacturing method therefor Active 2040-07-31 US11296573B2 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
JP2019074476A JP6752323B1 (en) 2019-04-10 2019-04-10 Stator winding of rotary electric machine and its manufacturing method
JP2019-074476 2019-04-10
JPJP2019-074476 2019-04-10

Publications (2)

Publication Number Publication Date
US20200328647A1 US20200328647A1 (en) 2020-10-15
US11296573B2 true US11296573B2 (en) 2022-04-05

Family

ID=72333515

Family Applications (1)

Application Number Title Priority Date Filing Date
US16/827,920 Active 2040-07-31 US11296573B2 (en) 2019-04-10 2020-03-24 Stator winding for rotating electric machine, and manufacturing method therefor

Country Status (3)

Country Link
US (1) US11296573B2 (en)
JP (1) JP6752323B1 (en)
CN (1) CN111817467B (en)

Families Citing this family (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR3105640B1 (en) * 2019-12-20 2021-12-03 Valeo Equip Electr Moteur electrical conductor for a coiled part of a rotating electrical machine
JP2023017570A (en) * 2021-07-26 2023-02-07 株式会社デンソー Stator and stator manufacturing method
CN218276241U (en) * 2022-08-18 2023-01-10 合肥汉之和新材料科技有限公司 Hairpin coil, hairpin winding and hairpin motor
CN115383303A (en) * 2022-09-01 2022-11-25 深圳泰德激光技术股份有限公司 Copper wire welding method, device and computer-readable storage medium
DE102022211234A1 (en) * 2022-10-24 2024-04-25 Zf Friedrichshafen Ag Conductor arrangement and coil arrangement with conductor arrangement
FR3158659A1 (en) * 2024-01-30 2025-08-01 Ampere Sas PROCESS FOR ASSEMBLING TWO METAL BARS BY WELDING

Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20020033649A1 (en) * 2000-09-12 2002-03-21 Atsushi Oohashi Stator of dynamo-electric machine and manufacturing method therefor
US20030067239A1 (en) 2001-10-05 2003-04-10 Denso Corporation Stator arrangement of vehicle AC generator
JP2009081980A (en) 2007-09-27 2009-04-16 Hitachi Ltd Rotating electric machine and its stator
US7615906B2 (en) * 2005-05-24 2009-11-10 Hitachi, Ltd. Joint structure of electric wire, stator of rotary electric machine, method for manufacturing the same
JP2014036562A (en) 2012-08-10 2014-02-24 Denso Corp Multi-gap type rotary electric machine
US20160190891A1 (en) * 2014-12-26 2016-06-30 Toyota Jidosha Kabushiki Kaisha Rotary electric machine stator and manufacturing method of same
WO2016103989A1 (en) 2014-12-26 2016-06-30 日立オートモティブシステムズ株式会社 Rotating-electric-machine stator coil, rotating-electric-machine stator provided with said coil, and rotating electric machine provided with said stator
US20180248430A1 (en) * 2015-09-25 2018-08-30 Hitachi Automotive Systems, Ltd. Rotating Electric Machine and Method of Manufacturing Same
US10348148B2 (en) * 2016-03-17 2019-07-09 Denso Corporation Stator for rotating electric machine
US10763730B2 (en) * 2015-08-10 2020-09-01 Aisin Aw Co., Ltd. Insulating resin coating method and stator
US10992197B2 (en) * 2017-01-13 2021-04-27 Denso Corporation Stator for electric rotating machine

Family Cites Families (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5746641A (en) * 1980-09-03 1982-03-17 Matsushita Electric Works Ltd Iron-coreless armature
JPS59145271U (en) * 1983-03-17 1984-09-28 株式会社東芝 Winding wire of rotating electric machine
JP2002119003A (en) * 2000-10-10 2002-04-19 Mitsubishi Electric Corp Stator of rotating electric machine and method of manufacturing the same
JP2004229460A (en) * 2003-01-27 2004-08-12 Mitsubishi Electric Corp Rotating electric machine stator
JP5585819B2 (en) * 2010-03-31 2014-09-10 株式会社デンソー Rotating electric machine stator
JP2012139075A (en) * 2010-12-28 2012-07-19 Hitachi Automotive Systems Ltd Rotary electric machine
WO2016046889A1 (en) * 2014-09-22 2016-03-31 三菱電機株式会社 Stator of rotating electrical machine
JP6390672B2 (en) * 2016-08-02 2018-09-19 トヨタ自動車株式会社 Laser welding method for flat wire
DE102016220863A1 (en) * 2016-10-24 2018-04-26 Robert Bosch Gmbh Method for connecting flat wire ends and stator produced in this way

Patent Citations (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20020033649A1 (en) * 2000-09-12 2002-03-21 Atsushi Oohashi Stator of dynamo-electric machine and manufacturing method therefor
US20030067239A1 (en) 2001-10-05 2003-04-10 Denso Corporation Stator arrangement of vehicle AC generator
JP2003116242A (en) 2001-10-05 2003-04-18 Denso Corp Alternating current generator for vehicle
US7615906B2 (en) * 2005-05-24 2009-11-10 Hitachi, Ltd. Joint structure of electric wire, stator of rotary electric machine, method for manufacturing the same
JP2009081980A (en) 2007-09-27 2009-04-16 Hitachi Ltd Rotating electric machine and its stator
JP2014036562A (en) 2012-08-10 2014-02-24 Denso Corp Multi-gap type rotary electric machine
US20160190891A1 (en) * 2014-12-26 2016-06-30 Toyota Jidosha Kabushiki Kaisha Rotary electric machine stator and manufacturing method of same
WO2016103989A1 (en) 2014-12-26 2016-06-30 日立オートモティブシステムズ株式会社 Rotating-electric-machine stator coil, rotating-electric-machine stator provided with said coil, and rotating electric machine provided with said stator
US20170346358A1 (en) * 2014-12-26 2017-11-30 Hitachi Automotive Systems, Ltd. Rotary-Electronic-Machine Stator Coil, Rotary-Electric-Machine Stator Having the Same, and Rotary Electric Machine Having the Same
US10763730B2 (en) * 2015-08-10 2020-09-01 Aisin Aw Co., Ltd. Insulating resin coating method and stator
US20180248430A1 (en) * 2015-09-25 2018-08-30 Hitachi Automotive Systems, Ltd. Rotating Electric Machine and Method of Manufacturing Same
US10348148B2 (en) * 2016-03-17 2019-07-09 Denso Corporation Stator for rotating electric machine
US10992197B2 (en) * 2017-01-13 2021-04-27 Denso Corporation Stator for electric rotating machine

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
Communication dated Jun. 2, 2020, from the Japanese Patent Office in Application No. 2019-074476.

Also Published As

Publication number Publication date
JP6752323B1 (en) 2020-09-09
JP2020174449A (en) 2020-10-22
CN111817467B (en) 2023-02-17
US20200328647A1 (en) 2020-10-15
CN111817467A (en) 2020-10-23

Similar Documents

Publication Publication Date Title
US11296573B2 (en) Stator winding for rotating electric machine, and manufacturing method therefor
CN107005116B (en) Stator coil for rotating electrical machine, stator for rotating electrical machine having the coil, and rotating electrical machine having the stator
CN112335157B (en) Stator of a rotating electrical machine and a rotating electrical machine having the stator
US20220352796A1 (en) Method of manufacturing stator
JP6848131B1 (en) Stator and how to manufacture the stator
JP2023017570A (en) Stator and stator manufacturing method
CN108141083A (en) Electric rotating machine and its manufacturing method
JP2019017223A (en) Rotating electric machine stator
JP2019134539A (en) Stator coil of rotary electric machine
CN115411863A (en) Stator
JP6590872B2 (en) Manufacturing method of stator of rotating electric machine
JP7020121B2 (en) How to form a stator coil for a rotary electric machine
JP7514255B2 (en) Manufacturing method of stator for rotating electric machine, stator for rotating electric machine, and rotating electric machine
JP7166109B2 (en) Rotating electric machine stator
US10886823B2 (en) Stator for rotary electric machine, rotary electric machine, and method for manufacturing stator for rotary electric machine
US20120019085A1 (en) Rotary electric machine armature
JP7146137B2 (en) stator
JP2017034826A (en) Resolver
JP6922118B2 (en) Stator manufacturing method
US12395026B2 (en) Stator for suppressing peeling of insulating coating
JP2021069182A (en) Stator of rotary electric machine
JP2023022764A (en) Stator and method for manufacturing stator
US20220173629A1 (en) Coil, and dynamo-electric machine
US20220294297A1 (en) Method for manufacturing stator coil of rotating electric machine and stator coil
JP2022076743A (en) Method for manufacturing stator of rotary electric machine

Legal Events

Date Code Title Description
AS Assignment

Owner name: MITSUBISHI ELECTRIC CORPORATION, JAPAN

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:KATSURAGI, KOTA;KAWAGUCHI, SHINJI;YASUDA, KOHEI;REEL/FRAME:052208/0715

Effective date: 20200121

FEPP Fee payment procedure

Free format text: ENTITY STATUS SET TO UNDISCOUNTED (ORIGINAL EVENT CODE: BIG.); ENTITY STATUS OF PATENT OWNER: LARGE ENTITY

STPP Information on status: patent application and granting procedure in general

Free format text: APPLICATION DISPATCHED FROM PREEXAM, NOT YET DOCKETED

STPP Information on status: patent application and granting procedure in general

Free format text: DOCKETED NEW CASE - READY FOR EXAMINATION

STPP Information on status: patent application and granting procedure in general

Free format text: NON FINAL ACTION MAILED

STPP Information on status: patent application and granting procedure in general

Free format text: RESPONSE TO NON-FINAL OFFICE ACTION ENTERED AND FORWARDED TO EXAMINER

STPP Information on status: patent application and granting procedure in general

Free format text: NOTICE OF ALLOWANCE MAILED -- APPLICATION RECEIVED IN OFFICE OF PUBLICATIONS

STPP Information on status: patent application and granting procedure in general

Free format text: PUBLICATIONS -- ISSUE FEE PAYMENT VERIFIED

STCF Information on status: patent grant

Free format text: PATENTED CASE

MAFP Maintenance fee payment

Free format text: PAYMENT OF MAINTENANCE FEE, 4TH YEAR, LARGE ENTITY (ORIGINAL EVENT CODE: M1551); ENTITY STATUS OF PATENT OWNER: LARGE ENTITY

Year of fee payment: 4